Specific duties:

• Ensures suppliers meet ISO9001/TS16949 requirements. Develop suppliers to meet increasing quality requirements/expectations.
• Prepares and maintains policies, procedures, and manuals for North America on the determination of new supply sources, supplier quality relations, standardization of measurements, and acceptable criteria of materials.
• Conducts audits of suppliers' quality control systems, quality capabilities, processes, and facilities, which may involve exposure to a variety of environmental conditions. Determine advisability of changing or adding sources of supply.
• Interfaces with plant personnel to resolve chronic or major supplier issues and verify that suppliers understand process/product requirements.
• Reviews engineering specifications to determine suppliers' abilities to meet parameters and reviews new and modified product designs from a material standpoint advising modifications when necessary.
• Administers NA Supplier Performance programs for critical material and all nonconforming material. Monitors suppliers' corrective action plans and tracks supplier ppm's

ISO/TS 16949:2002 Lead Auditor

• Scope
• Normative Reference
• Terms and Definitions
• Quality Management System
• Management Responsibility
• Resource Management
• Production Realization
• Measurement. Analysis and Improvement
• How to manage Internal Audit Team
• How to setup an Internal Audit and Conduct Internal Audit
• How to write-up findings and communicate
• How to conduct an Opening Meeting
  · How to conduct a Closing Meeting
  

Definition:

ISO/TS 16949 is the only standard recognized worldwide related to quality management as it applies to any organization active in the automotive/motorcycle supply chain. It is based on:
1. The eight quality management principles (all fundamental to good business practice): /Customer focus /Leadership /Involvement of people /Process approach /System approach to management /Continual improvement /Fact based decision-making /Mutually beneficial supplier relationships
2. Fulfilment of customer specific requirements.

Who should take this online training?

• You want to quickly and efficiently understand what ISO/TS 16949:2002 and ISO 9001:2000 are about.
• You want to upgrade your knowledge and expertise from QS 9000 or ISO 9000:1994 to ISO/TS 16949:2002.
• You do NOT have time to allocate a full day to take a LIVE class on ISO/TS 16949:2002.
• You want to train more of your staff on ISO/TS 16949:2002 economically and without having to immobilize them in a class for a full day.
  
  

What the Participant Will Learn

The requirements of ISO/TS16949:2002

• How to prepare to conduct an internal audit
• Communication before and during the audit
• How to manage audit meetings
• How to properly write findings; major, minor, observation, & opportunity for improvement
• How to manage the documentation and records surrounding the internal audit activity
  

Upon completion, you will be able to:

• Ensure implementation is effective and practical
• Minimize wasted effort
• Plan, organize and support transition efforts
• Recognize pitfalls and avoid them before they happen
• Understand customer satisfaction & continual improvement
• Recognize and take advantage of opportunities to add value to the auditing and implementing processes
• Review and evaluate documentation for effectiveness and compliance to the standard
• Use common sense interpretations of the intent of the ISO/TS 16949:2002 clauses

We are measuring our processes and using the data for continual improvement?

• Continual Improvement is Being Derived from Use of the Process Metrics ·
• Process Metrics are in Place
• Process Maps and Metrics Established
• Process Maps Available, No Metrics
• Processes and Metrics are not defined

Working towards ISO/TS16949 accreditation

Aims Management Consultants capabilities are in line with our customers expectations of a professional first tier supply partner.
Working towards ISO/TS16949 standards, the project management system is compliant with the customers QMS, and all projects are the responsibility of a dedicated programme manager, managing a cross functional team, reporting directly to the management team.
has the relevant and appropriate in-house skills in industrial, mechanical, electrical and electronic design, and has the necessary experience in the utilisation of appropriate tools including CAD, in order to ensure the design concepts are best matched to the customer and end-user requirements. The ability to analyse designs by finite element techniques enables the designs to be validated without physical prototyping, resulting in a significant reduction in both development costs and time to market.Physical testing and design verification is undertaken in-house, working towards ISO/TS16949 standards, these testing capabilities ensure that cost and time is reduced and controlled throughout the verification process.

Main topics of implementation and documentation.

• Management System Documentation
• Development of Flow-Diagrams and Process Map
• Development Management System Policies and Manual
• Development of Procedures and Work Instructions
• Development of Management System Implementation Plan
• Ideas for Management System Integration

Why Automotive Certification to ISO/TS 16949 or QS9000?

• Industry aligned systems optimize certification audits. The benefits of such a scheme include
• Improved product and process quality
• Greater confidence towards global sources
• Reassignment of supplier resources to quality improvement
• Reduction in variation of quality
• Increased efficiency of production
• Common language to improve understanding of quality requirements hence reducing confusion
• Cost advantage
  

What business areas are affected by an ISO/TS 16949 quality management system?

Directly impacted are the functions directly involved in the process of meeting customer needs. That means your marketing people, design department, purchasing, production / service delivery, warehousing, transportation, etc. Impacted also are certain support functions, including maintenance, training / human resources, and purchasing. About the only significant part of your organization not generally taken under the quality management system umbrella is finance.

Some potential benefits of certification

• Certification provides a clear indication of your commitment to quality
• Focused sector scheme allowing for a common approach
• Delivers cost savings
• Improved operational efficiency
• Increases customer confidence
• Proof of certification is often a condition of the supply of goods and services

Where did ISO/TS 16949 come from?

Beginning in 1994 with the successful launch of QS 9000 by DaimlerChrysler, Ford and GM, the Automotive OEM's recognized the increased value that could be derived from an independent quality system registration scheme and the efficiencies that could be realized in the supply chain by commonizing system requirements. In 1996, the success of these efforts led to a move towards the development of a globally accepted and harmonized quality management system requirements document. From this, the International Automotive Task Force (IATF) was formed to lead the development effort.

What actions should be taken?

• Containment of any parts shipped, in production and in stock
• Investigation of problem and root cause:
• Design, Material
• Production methods
• Handling, Preservation
• Training
• Definition of customer requirements Etc.
• Agree corrective actions (in line with customer needs)

How Can Euro Quest help?

Whether you just want to get a better understanding of TS 16949 or need to become registered, Euro Quest can help. We provide a wide range of both public and on-site training geared to the requirements of TS 16949. Our consultants have broad experience providing quality initiatives to automotive suppliers, and we have assisted hundreds of organizations to obtain TS 16949 registration, all of whom have received registration on their first attempt.

Where did ISO/TS 16949 come from?

Beginning in 1994 with the successful launch of QS 9000 by DaimlerChrysler, Ford and GM, the Automotive OEM's recognized the increased value that could be derived from an independent quality system registration scheme and the efficiencies that could be realized in the supply chain by commonizing system requirements. In 1996, the success of these efforts led to a move towards the development of a globally accepted and harmonized quality management system requirements document. From this, the International Automotive Task Force (IATF) was formed to lead the development effort.

What are the Eligibility requirements for ISO/TS 16949:2002?

• ISO/TS 16949:2002 is relevant to automotive production and service part organizations only.
• It is applicable only to sites where production or service parts are manufactured. (A site is defined as: a location at which value added manufacturing processes occur. Manufacturing is defined: as the process of making production materials, parts or assemblies, or heat treating, painting, plating services.). Any tier within the supply chain can apply.
• Any potential supplier can only be accepted for registration if they have a documented request for quotation or is on a bid list of a subscribing customer.

Key requirements of ISO/TS 16949:2002

ISO/TS 16949:2002 focuses on an organization’s ability to realize its stated goals as well as achieve customer satisfaction by delivering conforming parts on time to customer specification at acceptable cost. ISO/TS 16949:2002 concentrates on the effective linkages in the company's business plan, quality policy, quality objectives and measures. The standard specifies how objectives can be achieved and deployed throughout the organization.

Why was the ISO/TS 16949:2002 Process Identification Tool developed?

The TS-2002 Implementation Work Group, a cross-functional AIAG committee of automotive industry participants, including Chrysler, Ford Motor Company, General Motors Corporation, IAOB, Federal Mogul, Delphi Automotive, American Axle, VCA Vehicle Certification, Robert Bosch, PPG Industries, Freudenberg NOK, Plexus training and other invited experts has developed an MS Excel™-based process identification tool. This tool is being provided FREE of charge to the automotive industry, whether you are an AIAG member or not. Registration to ISO/TS 16949:2002 requires suppliers to define and understand their internal processes in terms of the Technical Specification requirements. To that end, suppliers need a tool to map their processes to the requirements of the Technical Specification. Both Oversight and the Certification Bodies require a mapping of supplier processes to the ISO/TS 16949:2002 requirements to show that all processes have been assessed for each organization.

What are the main points of TS16949 and how will it affect non-automotive customers?

TS16949 represents a significant evolution over the current QS9000 quality/operating standard. TS16949 requires the manufacturer to look at each and every failure mode in detail, and perform studies to identify the root cause of each defect found in the process.
Once the root causes are identified, the manufacturer is required to implement changes programs to reduce these defects. This is a mandatory continuous improvement program that can be measured directly with defect rates. If a manufacturer that is TS16949 certified does not show continuous improvement with respect to defect rates, their certification can be withdrawn.

• Lower purchase prices as the manufacturer should be running at a lower in-process defect rate.
• Lower costs associated with line down issues as late product receipts will be dramatically reduced and nearly eliminated
• Lower reject rates at the end of the line associated with defective products from a TS16949 certified supplier.

Efficient Audit Tracking

provides a centralized Web-based repository for all audit documentation that makes search and retrieval easy. It provides advanced tracking capability every step of the way, from scheduling and planning to execution to completion. It offers best-practice audit forms for tracking basic audit information (scope, checklists, audit team, audit status, etc.) and information for each finding. It can be integrated with the CAPA process to track related CAPAs.

How is ISO/TS 16949 better than QS-9000?

1. Vehicle Manufacturers - VMs view:
   o Registration involves a generally more rigorous assessment, and is better guarantor of supplier performance,
   o increased emphasis on customer requirements,
   o less bureaucracy at all levels,
   o reduced variation in assessment (performance),
   o better control of the registration and assessor training process,
   o Focus on continual improvement.

Will the above quality standards be replaced by ISO/TS16949?

No. Plans for the withdrawal of these standards have not yet been announced. DaimlerChrysler, Ford and GM intend to make an announcement regarding the future of QS-9000 during the second quarter of 2002. The future of the other standards should be confirmed around the same time.

Product and Process Auditing for ISO/TS 16949:2002 Seminar Content

This is a two day course for auditors who need to conduct the manufacturing process and product audits on the plant floor as required by ISO/TS 16949:2002. The first day of the course teaches auditing fundamentals including performance based auditing, planning the audit and writing nonconformities. The second day of the audit examines a customizable plant floor manufacturing-based process/product checklist. What does the checklist mean? How do you sample? How do you ensure shop floor standardization? For DCX suppliers, on the second day aims management consultants can cover the use of layered audits and the use of layered auditing for process and product audits as well. This class shows organizations how to combine layered audits with manufacturing process audits and how to conduct product and process audits simultaneously with the same auditors.

What is the fate of QS 9000?

There are no plans to revise QS 9000 based on the new ISO 9001:2000 Standard. The agreement between QS-9000 and ISO, Geneva, to include ISO 9000:1994 text in the QS-9000, 3rd Edition, standards document expires on 14 December, 2006. Beyond that date, ISO/TS 16949:2002 will replace QS-9000.To suppliers currently registered to QS-9000: it is strongly urged that your registered site(s) upgrade to ISO/TS 16949:2002 at the expiration of their current QS-900 Certification, and no later than 14 December 2006 or earlier based on individual OEM customer requirements.

What the Participant Will Learn

• The requirements of ISO/TS16949:2002
• How to prepare to conduct an internal audit
• Communication before and during the audit
• How to manage audit meetings
• How to properly write findings; major, minor, observation, & opportunity for improvement
• How to manage the documentation and records surrounding the internal audit activity

A Single Set of Quality Requirements for the Automotive Industry

ISO/TS 16949:2002 provides a single set of quality requirements for the automotive industry, aligning multiple automotive quality system standards including QS-9000 (North America), VDA 6.1 (Germany), AVSQ (Italy) and EAQF (France). This regaitement is grotentially the single worldwide automotive industry standard for the future.
Developed by the International Automotive Task Force (IATF), ISO/TS 16949:2002 harmonizes various supplier quality system requirements for the design and development, production, installation and servicing of automotive-related products.
Automotive suppliers can save cost by maintaining one quality system certification to meet multiple customer requirements.

Employee Motivation and Empowerment

The organization must have a process to motivate employees to achieve quality objectives, to make continual improvements, and to create an environment to promote innovation. The process must include the promotion of quality and technological awareness throughout the whole organization.
The organization must have a process to measure the extent to which its personnel are aware of the relevance and importance of their activities and how they contribute to the achievement of quality objectives

Engineering Specifications

The organization must have a process to assure the timely review, distribution, and implementation of all customer standards, specifications, and changes based on the customer-required schedule. A "timely review" is as soon as possible and must not exceed two work weeks.
The organization must keep a record of the date on which each change was implemented in production. Implementation must include updated documents.

Moving your business forward

ISO/TS 16949 specifies the quality system requirements of automotive related products. In addition, there are customer specific requirements that are required by individual subscribing vehicle manufacturers.
Certification to ISO/TS 16949 reduces production variations and increases overall efficiency, reduces the number of second party audits, and provides a common quality system approach to the entire supply chain (for supplier / subcontractors) and accesses to the industry’s best practices.

The purpose of the new edition

• Provide clarification of requirements based on issues found during office assessment and witness audit
• Need to incorporate the existing 43 FAQ's and 9 SI's issued against the Rules for Achieving IATF Recognition: 2nd edition.
• Improved structure based around ISO/IEC 17021:2006

Scope of the Quality System

The Company operates a Quality System that complies with the requirements of ISO9001 for the range of products manufactured by the Company.Additionally, the Quality System complies with the requirements of TS16949:2002 for all products manufactured by the Company and supplied to the Motor Industry.Final products within the scope of TS16949:2002 are identified by the Part Number.
Dialight Aims Management Consultants operates a quality management system which complies with the requirements of BS EN ISO 9001: 2000 and TS16949:2002this assessment has been conducted in accordance with the requirements of TS16949:2002

The most important changes for certified organization

• When planning the date of the recertification audit, it must be ensured that the certificate decision is made before the expiry date of the existing certificate, but at the latest on the last day of validity. This means that all activities within the framework of a recertification audit must be completed before the certificate expires.
  Recommendation: the recertification audit should begin 3 months before the existing certificate expires.
• The certification body shall appoint at least one auditor from the initial certification audit team to participate in all surveillance audits of the three (3) year audit cycle.
• For each subsequent recertification and surveillance audits, different auditors shall be used.
• Remote supporting functions like development, purchasing, contract verification and extended worbenches need to be listed in a certificate appendix.

In-process Inspection and Test

In-process inspection/testing is conducted to ensure that the product/process conforms to specified requirements. The inspection/testing is normally carried out by production personnel. Random audits of the in-process inspection/testing process are conducted by quality control personnel.
The Quality Manager determines the extent and scope of in-process inspection/testing based on the importance of the item, control methods, and previous performance.

MONITORING AND MEASUREMENT OF PRODUCT

XYZ COMPANY measures and monitors the characteristics of the product/service to verify that requirements for the product/service are met. This is carried out at appropriate stages of the product/service realization process. Evidence of conformity with the acceptance criteria is documented. Records include the authority responsible for release of the product/service.

What is the format of ISO/TS 16949?

• ISO 9001/ 9002:1994 define the international quality system requirements
• Sector requirements define international automotive quality system requirements
• Customer specific requirements are required by individual IATF customer members

Aims Management Consultants services

Aims Management Consultants is recognized all over the world in the registration of automotive quality management systems as ISO/TS-16949 certifying body. Aims Management Consultants India's ISO/ TS 16949 certification is directed towards improved products and process quality, lower variation factors and optimum output efficiencies. Aims Management Consultants India today extends this certification to a large number of auto manufacturers in the country.

The certification process is a multiple-step process. The certification cycle is described briefly:

• Application for certification from client
• Offer from Aims management consultants India
• Offer acceptance from client and order confirmation by aims management consultants India
• Preaudit (optional)
• Certification audit
• Issue of certificate on successful completion of certification audit
• Surveillance audits at defined interval
  

ISO/TS 16949:2002 Transition Training

This course is designed for organizations who are currently using ISO 9001:1994/QS-9000 and need to upgrade to ISO/TS 16949:2002.
This course will help your company:

• Understand the requirements
• Develop a detailed transition plan
• Proceed in a timely, cost effective manner, take advantage of the existing structure supplied by your current Quality Management System
• Understand the new obligations directed or implied within ISO/TS 16949:2002 requirements and leverage similarities between the old and new requirements

The benefits of adopting this standard are numerous:

• Increased efficiency and improved quality
• Common quality system approach in the supply chain for development and consistency
• Ensuring that the organization works more effectively
• Reduction of variation and increase in efficiency
• Reduction in multiple third party registrations freeing up time and supplier resources for other quality activities and improvement opportunities that can enhance business.

Fundamentals of TS16949:

• Definition of Quality
• Quality Control
• Automotive Quality Assurance
• Why TS16949?
• When to pursue TS16949?
• Benefits—tangible and intangible
• How TS16949 integrates with your overall company improvement program
• Typical costs
  Initial registration
  On-going maintenance
• History of TS16949
• Applicable standards & guidelines
• The registration process
• Internal and external audits
  
  

ISO/TS 16949 AND QS 9000

QS 9000 is the Automotive Standard developed and controlled by the Big 3 in America (Chrysler, Daimler and Ford) QS 9000 adopted ISO 9001: 1994 and improved upon it by adding additional requirements.
ISO 9001:1994, on which QS-9000 is based, became obsolete on 15th December 2003.
However, the QS-9000 Supplier Quality Requirements Task Force (SQRTF) have been granted an extension of 3 years by ISO to continue to use ISO 9001:1994 in conjunction with QS-9000, and so QS-9000 will be valid until 14th December 2006.
Formal communications by the Big 3 regarding their particular requirements within this time scale were issued in August 2002.
If a client holds a certificate with a split scope (ie. part QS-9000, part ISO 9000), the element relating to QS-9000 will be reissued with new wording and be valid until December 2006.
The element relating to ISO 9000 will require upgrading to ISO 9001:2000 - this would result in the issue of separate certificates.